Novel method and composition of matter



United States Patent filice 3,371,125 Patented Feb. 27, 1968 ABSTRACT OF THE DHSCLOSURE Oxidative dehydrogenation through the use of niobium catalyst. The specific catalyst is:

M O -Nb O -A O in the metal atom ratios 0.05 to :1:0 to 2 respectively. M is tungsten or chromium, and A is alkali or alkaline earth metal. X and Y represent valences of their respective metals.

This invention relates to the oxidative dehydrogenation of hydrocarbons for the production of unsaturated hydrocarbons and the like. More specifically, this invention relates to dehydrogenation of alkylaromatic compounds to unsaturated alkylaromatics in the presence of oxygen, whereby suificient heat is generated by the exothermic nature of the reaction, so as to reduce the external heat ordinarily required for the dehydrogenation. This invention also relates to novel catalysts utilized in promoting the dehydrogenation, whereby excellent selectivity and conversion are obtained.

It is known in the prior art that ethylbenzene compounds may be dehydrogenated to styrene at atmospheric pressure by externally supplying heat so as to bring the reactants up to a reaction temperature, usually temperatures of 600-650 C. In one process, superheated steam is mixed with 6-10 mol percent ethylbenzene to reduce the partial pressure of the hydrocarbon, supply heat for the endothermic reaction and to remove coke by the water-gas reaction, which is ordinarily deposited on the catalyst.

The superheated steam, usually at about 710 heated to 500 C. The

mixed with ethylbenzene, is C., While the ethylbenzene is premixture enters the base of a fixed bed reactor at 600 to 620 C. The inlet temperature is usually raised to 660 0., however, as the catalyst ages and loses some of its activity. The heated ethylbenzene is passed through the reactor at a space velocity of approximately 0.7 to 1.0 v./hr./v., which is defined as liquid volumes of reactant at Standard Temperature and Pressure per hour per volume of catalyst. The products of the reaction leave the reactor at 560 C., are cooled, passed through a spray column and condensed in a heat exchanger. Water and oil phases thus obtained are separated in a gravity separator, while non-condensed gases are compressed and chilled to obtain maximum recovery of aromatic hydrocarbon by-products.

In a conventional or non-oxidative dehydrogenation process the feed is pre-heated somewhat above reaction temperature. The major portion of the conversion occurs in the inlet portion of the catalyst bed, since the reaction is endothermic and as the reactants move along the catalyst bed they are progressively cooler. This type of temperature profile results in poor performance because of two effects. At these lower temperatures, the rate of reaction of ethylbenzene is naturally low. Furthermore, the equilibrium for the dehydrogenation reaction becomes less favorable at the low temperature. Hence, conversion is quite limited in this type of process. If the temperature in the inlet portion of the bed is raised, cracking and coking become extensive and prevent non-regenerative be effected by thelat-ter operation. Control of the temperature near the exit sec-. tion of the catalyst bed by external heating is not easily accomplished. Liquid heating media are not stable at these high temperatures; close control by gaseous fluids is diflicult.

Catalysts generally used consist of the oxides of iron,

potassium, magnesium and copper. Other commercially available catalysts include iron oxide promoted with potassium carbonate and chromium oxide. Additionally, calcium-nickel-phosphate catalysts are used to this end. Ordinarily, these catalysts operate non-regeneratively with a life of approximately one year. Commercial operations are benefitted by catalysts and processing conditions which yield a selectivity of percent or better and overall,

conversion of 50 percent or better, however, these conditions are not always achieved. In fact,,typical commercial conversion values are only 35-40 percent.

The chemistry of dehydrogenation, as illustrated by the production of styrene by dehydrogenation of ethyl-.

benzene, may best be represented by the equilibrium reaction:

H Catalyst C2Hs A =CH2 Thus, it can be seen that the conversion is limited by chemical equilibrium. With this limited conversion of the feed, recycling of the ethylbeuzene is required, necessitating costly separation facilities.

More efiicient methods are directed to removal of hydrogen to promote a shift in the equilibrium to favor production of the unsaturated hydrocarbon. Oxidative dehydrogenation reactions in which oxygen is added to the system in the presence of a suitable catalyst, avoid the equilibrium limitation imposed upon the dehydrogenation reaction as illustrated by the following reaction:

02 catalyst and higher conversions to alkyl benzenes such as styrene are thus possible without extensive recycling of ethylbenzene.

Basically, two types of oxidative dehydrogenation systems are known in the prior art. In one system, ethylbenzene and oxygen are reacted in the presence of a halogen, such as iodine, bromine or chlorine. Generally, a solid catalyst is also employed. The other system involves addition of oxygen to the hydrocarbon feed in the absence of any halogen additive. This reaction is also carried out in the presence of a solid catalyst. The former process involves conversions of ethylbenziene to styrene in the presence of molten lithium iodide at conversion temperatures of 543? C. and oxygen-ethylbenzene ratio of 0.45, whereby a liquid product is obtained containing 23 percent ethylbenzene and 77 percent styrene. Lithium iodide is subsequently converted into lithium oxide and iodine by oxidation, whereby the iodine produced effects the dehydrogenation and hydrogen iodide is produced as a by-product. Hydrogen iodide and lithium oxide subsequently react to form the starting material lithium iodide. The iodine catalyst is thus formed in situ. The catalyst and molten lithium iodide and lithium oxide, however, are highly corrosive and, consequently, difficult to handle. The production of u-methylstyrene and styrene may process in the presence of gaseous iodine by conversion of isopropylbenzene and ethylbenzene to the extent of 36 percent and 29 percent respectively, at selectivities of approximately 40 percent at 700 C. and oxygen-feed ratios of 0.5. Halogen-containing compounds, however, are also produced with the styrene and are undesirable because of difiiculties in purifying the unsaturated hydrocarbons produced. The relatively low yields obtained also make this process commercially undesirable.

In a non-halogen system, calcium-nickel-phosphate catalysis of ethylbenzene at 500 C. is efiected for the production of styrene. Conversions to styrene may be increased from 36 percent to 45 percent by the addition of 0.15 moles of oxygen per mole of ethylbenzene feed, according to the process; however, selectivity decreases from 88 percent to 86 percent. Addition of oxygen to the feed at higher temperatures results in a higher loss of selectivity. This and maximum conversions of 45 percent make this process undesirable from a commercial standpoint.

Thus, the prior art catalyst precursors such as lithium oxide/lithium iodide in a molten condition are difiicult to handle because of their corrosive nature. Halogen catalysts or processes present a difiiculty of halogen-contamination of the unsaturated products. Additionally, some of these processes result in conversions lower than 50 percent and selectivities lower than 85 percent, which make them commercially undesirable. Additionally, prior art systems are characterized by the application of externally supplied heat to initiate and maintain the dehydrogenation.

It is therefore an object of this invention to provide a novel method and catalyst for the oxidative dehydrogenation of alkyl-cycloaliphatic and alkyl-aromatie organic compounds at selectivities of 85 percent and greater and a conversion of 50 percent and greater, where styrene is obtained, and at least 25 percent conversion at selectivities of 50 percent where styrene derivatives are obtained.

Another object of this invention is to provide a process for the oxidative dehydrogenation of alkyl-aromatic compounds for the production of styrene and its homologues and analogues.

A further object of this invention is to maintain the reactor temperature in such a process while introducing a minimum of heat.

Additionally, it is an object of this invention to maintain a balance between the heat absorbed and the heat produced in the oxidative dehydrogenation reaction of this invention.

It is a further object of this invention to provide an oxidative dehydrogenation catalyst that is relatively simple to manufacture and use.

It is a further object of this invention to provide a novel oxidative dehydrogenation catalyst free from halogens.

These and other objects of the invention have been accomplished by the dehydrogenation of organic compounds of the formula where R=any organic compound or hydrogen, n=13,

and Y=methyl or hydrogen, or of the formula i X--CJCH;

4 tion of organic precursors of styrene, its homologues and analogues within the definition of the above formulae, preferably by the oxidative dehydrogenation techniques and by means of a novel catalyst. Any combination of the above reactants is also suitable for the purpose of this invention.

The process of this invention is especially directed to the dehydrogenation of ethylbenzene to form styrene and isopropylbenzene to form a-methyl styrene or their homologues and analogues by dehydrogenation of their hydrogenated precursors.

The reaction is promoted by a catalyst comprising the oxides or niobium combined with the oxides of chromium or tungsten and, optionally, containing at least one memher selected from the group consisting of the oxides of the alkali metals or alkaline earth metals. The composition of the catalyst may be varied from 0.05 atoms of chromium or tungsten per atom of niobium to 10.0 atoms of chromium or tungsten per atom of niobium and from 0.01 atom of alkali metal or alkaline earth metal per atom of niobium to 2 atoms of alkali metal or alkaline earth metal per atom of niobium. The catalyst may be used without a support or may be coated or deposited on an inert support such as fused alumina, silicon carbide, alumina or silica gel, etc. The catalyst may be used in the form of granules of pellets in a fixed bed reactor or may be used in the form of powder in a fluid bed reactor.

The catalyst of this invention may be characterized by formula:

a/x s z s a/r in the metal atoms ratios of 0.05 to 10:1:0 to 2 respectively, where M is selected from at least one member of the group consisting of chromium and tungsten and x is the valence of M, and A is selected from at least one member of the group consisting of alkali metals and alkaline earth metals, and y is the valence of A.

The conversion is conducted at temperatures of 400 to 750 C. and oxygen to hydrocarbon mole ratio of 0.05 to 1.0, particularly 0.7 to 2.8 liquid volumes of hydrocarbon feed per hour per volume of catalyst. Oxygen is normally added as air; however, pure oxygen or oxygen in combination with a diluent gas can also be used. The entire oxygen-containing gas may be added to the reactor inlet, or oxygen-containing gas may be injected at a number of points along the reaction Zone to reduce the selectivity to carbon oxides.

Concentration of hydrocarbon in the total reactor feed may be varied from 1 mole percent to 50 mole percent, although about 10-20 mole percent is normally used. Concentration of hydrocarbon in the total reactor feed may be adjusted by the addition of steam.

The hydrocarbon conversion may be carried out by feeding hydrocarbonoxygen-diluent mixture to the catalyst zone for a period of 10 minutes to 10 hours, after which the feed mixture is stopped and the catalyst is regenerated with air, whereby carbon deposits on the catalyst are removed as carbon oxides. Alternately, the hydrocarbon conversion may be carried out non-regeneratively, whereby hydrocarbon-oxygen-diluent mixture is fed continuously to the catalyst zone without intermittent periods of regeneration. With non-regenerative operation, it is generally advantageous to use steam as a portion of the inert diluent.

The hydrocarbon feed and oxygent are mixed in the proper mole ratios before being introduced into a catalytic reaction chamber, or may be introduced separately. The ingredients may be heated by means of steam or other heat sources prior to introduction into the catalytic chamber. Alternately, the reactants may be brought into contact with the catalyst at ambient temperatures and heat supplied to the reaction chamber. The exothermic nature of the oxidative dehydrogenation, wherein water is produced as one of the by-products, enables the reaction to be conducted with substantially lower quantities of external heat. The exotherm which results from the oxidation of the hydrogen by-product of the reaction, is used to maintain the hydrocarbon at the reaction temperature require-d for dehydrogenation, along with externally in- 6 purpose of this invention in terms of percent heat bal ance, which is the percent of the endothermic heat of dehydrogenation required for ethylbenzene and its equivalents enumerated herein, which is supplied by the heat troduced heat. 5 released during the combination by-product of hydrogen While the conventional process is limited by reaction with oxygen. and equilibrium considerations, the process of this in- Thus, the heat balance may vary from 0-200 percent, vention permits maintaining temperature in the bed at a and preferably 20-180 percent, or from 50-150 percent. more nearly constant level, eifecting high rates and elirn- Twenty to 180 percent heat balance corresponds to apination of equilibrium restrictions by conversion of hy- 10 proximately 10-90 percent reaction of hydrogen with drogen to Water. oxygen in the case of ethylbenzene feed, and 50-150 It was observed that, when using the catalyst and percent heat balance to approximately 25-75 percent remethod of this invention, the activation energy for the action of hydrogen. Similarly, 0-200 percent heat bal oxidative dehydrogenation of hydrocarbons was su'bstanance indicates that the reaction may be conducted withtially lower than in the non-oxidative process. For eX- out oxygen, or with suflicient oxygen to convert all hyample, with ethylbenzene, the activation energy for the dr gen released from the reaction to water. Thus, the reaction in the absence of oxygen is 29.1 kilocalories. heat balance is partially controlled by the addition of Activation energies for the oxidative dehydrogenation of y d such yg n a dit n my be xpr s d i ethylbenzene using oxygen/ethylbenzene ratios of 0.17, terms of heat balance, (3-200 P 204180 P 0.25 and 0.50, was 22 kilocalories, the significant feature Cent and 50-150 Percent of this discovery being that the present invention permits The hydrocarbon Conversions f selectlvltfes y the oxidative dehydrogenation of various hydrocarbons at t that, Where s y n 1s obtamed, conversions ergconsiderably lower heat imputs than by previously known Proxlmately comp! at least 5O PeICeI1ll at selectlvl' methods, and thus represents a substantial savings in fuel, tles at least 85 percent a Qoflverslons of especially in wmmercial operations 25 hydrocarbons tostyrene derivatives comprise at least 25 The catalysts of this invention are prepared by reacting Pereent at'seleetlvltles of at least 50 Percent proportionate amounts of soluble catalytic oxide precur- The Venous eatalyst? used f the frf of sor compounds in solution for a length of time so that hydrocarbons along W Venous leonverelon P e E a precipitate is formed after which the precipitate is calare more Y deseneed the fellewmg cined. The calcined precipitate may be further treated examples f F glven Preferred embedl with K 0 or other alkali and/ or alkaline earth metal oxide and M10135 of the mvennon, e e not to be precursors such as a Water solution of potassium hydroxconstrued Parrowmg the novel mventlve method ide, alcoholic potassium hydroxide and the like, Where i i e of matter of the ePPhFant- Unless other catalysts containing potassium are to be prepared. The W186 Speclfied, ff e f} 15 used as e diluent gas alkali metals used in this regard comprise Li, Na, K, Rb amples and all ratlos are molar ratlosand Cs, whereas the alkaline earth metals comprise Ca, Examples I and II.-Tungsten-niobiumcatalysts and other operable Group A and H A ele- Catalysts containing tungsten and niobium are prements Mg correspondmg to the above ared b mixin solutions of ammonium metatun state alkali and alkaline earth metals, may be used. Any com- 5 igm ofalate Eva Gratin excess water y g bination of i i f alkali and/Or i i earth metals 40 and calcining at 500 C. atalysti containing W /Nb ramay be used in additlon to any comblnation of the above tics from 0.8 to 85 are thus prepared elements referred to. The above alkali and/or alkaline Conversion of fithylbanzene (EB) with these catalysts earth compounds will be referred to in the specification is conducted at temperatures of 675 and 7000 C a space and claims hereof as alkaline compounds. Precipltates velocity of 1,3 v /hr./v. and o /ethylbenzene (O /EB) treated in 811011 a manner are. calcined a Second time ratios of 0.25 and 0.50. Conversions and selectivities ob- A'rnmonium hydroxide is conveniently added to the tained at 675 and 700 C. are given below:

Ex. Catalyst 01 121; 675 &

Percent Percent Percent Percent Conv. Selec. Conv. Selec. I rowoi-onNbioi 0. 25 47 st 56 83 II 1.0W0 -L0Nbq05 0. 2s 43 83 54 83 metal oxide precursors to adjust pH of the solution to facilitate precipitation.

The oxide precursor compounds referred to generally comprise the organic and inorganic salts of the catalyst metals, such as the nitrates and oxalates of chromium and niobium, or ammonium salts of the catalyst metals, such as ammonium tungstates or chormates. Other metal oxide precursor compounds are suitable so long as they are soluble. Thus, for example, W O -Nb O catalysts are prepared from ammonium metatungstate and niobium oxalate, and Cr O -Nb O catalysts are prepared from ammonium dichromate or chromium nitrate and niobium oxalate.

The reaction may be conducted so that the external heat added to initiate the dehydrogenation, may be reduced in an amount inversely proportional to the quantity of oxygen used. This relation will be defined for the It can be seen from the above data that tungsten-niobium catalysts give conversions of 43-56 percent and selectivities of 83-84 percent. Catalysts containing V/Nb ratios of 1.0 and 0.5 are similar in both activity and selectivity. Furthermore, tungsten-niobium catalysts have about the same activity, but unexpectedly higher selectivity than iron-niobium catalysts.

Examples III-VI.-Chr0miwm-ni0biwm catalysts 7 to 0.90. Conversions and selectivities obtained at 700 C. are compared below:

of cracking products and coke, as compared to similar catalysts containing no potassium.

Space 700 C. Ex. Catalyst Veloc Oz/EB v./hr./v Percent Percent Conv. Sclec.

LOCI'203-5Nb205 1. 3 0. 25 45 as 1 DCI OyKONlMOL. 1. 0. 25 59 85 l.0CrrOs-2.0l lbaO.s. 1.2 0. 25 s8 s4 1 ()ClaOs-LONbzOs 1. 5 0. 25 43 82 Thus, catalysts containing Cr/No ratios of 0.33 and Thus, a catalyst is prepared by adding an ammonium 0.50 give conversions of about 59 percent and selectivity hydroxide solution to a solution of chromium nitrate and of 8485 percent. Catalysts containing Cr/Nb ratios of niobium oxalate. The resultant precipitate is filtered, dried 0.2 and 1.0 give lower conversions and slightly lower and calcined at 500 C.Asolution of potassium hydroxide selectivities. Chromium-niobium catalysts prepared using in water is then added to the precipitate and is dried and ammonium dichromate solution are comparable in activcalcined a second time. The catalyst thus prepared comity and selectivity to tungsten-niobium catalysts. prises cr2O3'Nb2O5K2O in a mole ratio of 1:1:02 respectively. Example VII The catalyst comprising the oxides of niobium, chro- A Second Seiies Of chmmillm-niobium catalysts are mium and potassium thus prepared is utilized in promot- P p y adding an ammonium hydroxidfi Solution to ing the conversion of ethylbenzene to styrene. The condia solution of chromium-nitrate and niobium oxalate. tions and results f the Conversion are given below; The resulting precipitate is filtered, dried, and calcined at 500 C. A catalyst having Cr/Nb ratio of 1.67 is thus Catalyst;

re ared. P (gonversion of ethylbenzene with this catalyst is car- Temperature 700 650 ried out at temperatures of 625-725 C. space velocities g 8-3 of 0.7 to 2.8, and O /ethylbenzene mole ratios of 0.15 Percent Conversion s3 67 to 0.50. Conversion and selectivity obtained at 700 C. is gf sggfillli ii 59.8 899 given below: Benzene+Toluene 25.0 5.5 coke-.. 11.3 3.5 Ex. VII: 01-03-..- 2.8 0.3 Catalyst rocr o -nsNb o COZJFCO H M B" l The above results indicate that chromium-niobium cata- Conv percent (700 C) 63 ysts containing potassunn oxide are not only approxi- Selec percent (7000 C) 82 85 mately twlce as active as the calcium-nrckel-phosphate catalysts of Example VIII, but also, at 650 C., the cata- Activity of chromium-niobium Catalysts P p lysts containing potassium effected a 67 percent converfrom chromium nitrate increases as the Cr/ Nb ratio deign of h lb m Styrene at 90 percent salectivity, creases from 5.0 to 0.5, while selectivity of all catalysts Whgfeas the calciummickepphosphate Catalysts only gave of these Varying H101 ratios is in the range of 79-85 P 80 percent selectivity under comparable conditions. The conversion obtained with the above chromium-niobium- Activity and Selectivity of chrqmiummioblum potassium catalyst is approximately one-and-a-half to Y P QP Q 9 ammonium fhchfomate and chr0- twice that obtained in commercial operations. It can theremlum filtrate mdlcate that the nltr'ate'prePared Catalyst fore be seen that this novel catalyst and method represent is more active than catalysts prepared from the dichroa i ifi t advance in the Stats f the an mate. Highest activity in the nitrate series of catalysts is obtained in the composition range corresponding to Example XI Cr/Nbrati0sOf0-6t01-0. The following examples illustrate space velocity re- Generally speaking, the styrene selectivity of catalysts 5O quired to obtain 85 percent conversion of ethylbenzene prepared from either the dichrornate or chrominum niwith a catalyst comprising 1.0Cr O 1.0Nb O The methtrate are similar when compared at constant temperature d of Example I w utili d i btaining th results and space velocity. The catalyst prepared by the nitrate tabulated below, method, however, is more selective, generally speaking, than the catalyst prepared by the dichromate method, SpaceVelocity Reqd [or 85% Conv.,v./hr./v. when the two are compared at constant conversion ratios. Oz/ethylbenzene ratio Example VIII A commercially available calcium-nickel-phosphate Temperature; catalyst was tested for oxidative dehydrogenation of ethyl- 700 3%? 8-23 8- benzene at temperatures of 650 and 700 C. When oxygen 0:15 0: 22 0130 was not added to the feed (reactants), conversions of 20 percent and selectivity to styrene of 92 percent was ob- It can be seen from the above table that at 700 C. tained at 650 C. Addition of oxygen to the feed, equivaddition of 0.5 moles of oxygen increased catalyst activity alent to oxygen/ethylbenzene ratios of 0.5 at 650 C., by about 20 percent, compared to oxygen-free operations. increased conversion to 44 percent, however, selectivity At 600 (1,, ddition of 05 moles of oxygen increased the to styrene decreased from 92 percent to 83 percent. At catalyst a tivity by 100 percent, 700 C. and an oxygen/ethylbenzene mole ratio of 0.5, 55 percent conversion and 85 percent selectivity were Example XII obtained. Chromium-niobium catalysts containing an alkali Examples IX and X metal oxide are prepared by treating a chromium niobium It has been found that a chromium-niobium catalyst, catalyst Wuh sohguon. of an alkal} metal t The pregnated catalyst is dried and calcined at 500 C. Catatreated Wl'th potassium hydroxide, eliects conversion of 1 t th I r d m rig Cr 0 Nb 0 O hydrocarbons, such as ethylbenzene, to styrene at temys 5 us p epa e co p e 2 3 2 5 2 peratures lower than 700 C., with a minimal quantity Cr O -Nb O -Rb O 'and Cr O -Nb 'Cs 0 in 'a mole ratio of 1.1:1.0;0.175

respectively.

, Conversion of ethylbenzene with these catalysts is effected at a temperature of 650 C., space velocity of 0.60 liquid volumes per hour per volume of catalyst, O lethylbenzene mole ratio of 0.20 and percent concentration of ethylbenzene in the feed. Nitrogen or steam is used as a diluent. Conversions and selectivities obtained are given below:

Example XVI A feed containing a mixture of m-l-p-diethylbenzene is dihydrogenated over the l.0WO -1.0Nb O catalyst of Example II. Conversion with this catalyst is conducted at 675 and 700 C., at a space velocity of 0.6 v./hr./v.

This example clearly illustrates the beneficial role of oxygen in the feed. Using a Cr O -Nb O -0.18Rb O catalyst at 650 C., with ethylbenzene feed at 0.6 lv./v./ hr., and a l0-percent (mole) concentration of hydrocarbon in the feed with steam diluent, the following values are obtained:

Oxygen/ethylbenzene ratio Percent ethylbenzene conversion 36. 7 67 Percent selectivity:

Styrene 83. 8 83. 8 Benzene and toluene 10. 2 11.8

Reaction conditions according to the method of the invention are as follows:

Temperature C 625 Space velocity v./hr./v 0.8 O /EN mole ratio 0.4 Percent EN in feed (steam diluent) 12 Conversion of the ethylnaphthalene is 46 percent; selectivity for fi-vinylnaphthalene is 81 percent. The selectivity value for CO+CO formation is 7 percent.

Example XV Ethyl heterocyclic compounds are used to evaluate a supported oxidative dehydrogenation catalyst deposited on a-alumina. The catalyst composition is C1'203 4Nb O 0. 1 Reaction conditions, according to the method of the invention are as follows:

Space velocity v./hr./v 0.8

Percent concentration of organic in feed (steam diluent) l0 O /heterocyclic mole ratio 0.25

The following results are obtained:

Percent Selectivity Optimum Percent Compound Temp., Conv. Vinyl O. Hetero- C0+C0r cyclic 2-ethylpyridine. 625 51 81 6 2-etby1thlophene 685 74 69 22 No indication of catalyst poisoning is detected.

Catalyst ClzOa-NbzOs- CHO s-Nbzo 5- ClzOa-NbzOs- 0.175 K20 0.175 R1120 0.175 C520 Diluent N 2 Steam N; Steam N1 Steam Temperature, C 650 650 650 650 650 650 Space Velocity 0.6 0. 6 0.6 0.6 0.6 0. 6

O /Ethylbenzene, mole ratio 0.2 0.2 0.2 0.2 0.2 0.2

Percent Conversion 65 57 74 67 41 52 Percent Styrene Selectivity 86 85 82 84 86 Example XIII and O /DEB mole ratio of 0.52. The results obtained are as follows:

Percent Selectivity Percent Conversion Divinyl- Ethylvinyl benzene benzene Temperature, 0.:

Although the previous examples relate to the conversion of organic compounds by oxidative dehydrogenation, the conversion of other compounds is also contemplated and include: ethane, propane, propene, n-butane, butene, isobutane, n-pentane, l-pentene, 2-pentene, isopentane, 3- methyl-Z-butene, n-hexane, hexene, n-heptane, monomethylhexane, monomethylhexene, n-octane, n-octene, monomethylheptane, dimethylhexane, n-decane, S-methylnonane, 2,2,3-trimethylpentane, 2,4,4-trimethylpentcne, cyclopentane, cyclopentene, methylcyclop-entane, cyclohexane, methylcyclohexane, ethylcyclohexane, 1,3-dimethylcyclohexane, 1,4-dimethylcyclohexane, n-propylbenzene.

Thus, there has been described and illustrated a novel and inventive catalyst and method for the oxidative dehydrogenation of various organic compounds. A preferred catalyst for conducting the reaction comprises a mixture of the oxides of chromium or tungsten, niobium and potassium. The selectivities and conversions obtained with this particular catalyst are higher than those achieved with prior art processes and catalysts. The reaction is further characterized by an exotherm suflicient to reduce the total quantity of external heat required to maintain the reaction temperatures.

Although the invention has been described with reference to certain preferred embodiments, it is not the applicants intention to be limited thereby, and certain obvious modifications of the novel catalyst and method are intended to be included within the broad scope of the invention, as embodied in the following claims.

What is claimed is:

1. A dehydrogenation catalyst comprising Ms og Nbgo -A O in the metal atom ratios 0.05 to 10:1:0 to 2 respectively, where M is at least one member selected from the group consisting of chromium and tungsten, x is the valence of M, A is at least one member selected from the group consisting of alkali and alkaline earth metals and y is the valence of A. d

2. Catalyst as claimed in 1 wherein M is tungsten and A is potassium.

3. A method for manufacturing a to 10:1:0 to 2 respectively, where M is at least one member selected from the group consisting of chromium and tungsten and x is the valence of M, A is at least one member selected from the group consisting of alkaline earth metals and alkali metals and y is the valence of A, comprising dissolving amounts of soluble oxide precursors in an amount sufiicient to produce a product having said atom ratios of both M and niobium in a solvent, reacting said precursors until a precipitate forms, calcining said precipitate, adding an amount of an oxide precursor in an amount suflicient to produce a product having said atom ratios of A to said calcined precipitate and calcining said precipitate having said oxide precursors of A added thereto.

4. The method of claim 3, where said soluble oxide precursors of M, Nb and A are salts.

5. The method of claim 4, where said salts are inorganic salts.

6. The method of claim 5, where said soluble oxide precursor of M is chromium nitrate.

7. The method of claim 5, where said soluble oxide precursor of M is ammonium chromate.

8. Process of producing ethylenically unsaturated materials which comprises contacting oxygen and a compound of the formula:

wherein X is an aromatic or heterocyclic group; Y is selected from the group consisting of methyl and hydrogen, and n is 1 to 3 together in the presence of a catalyst as claimed in claim 1 at about 400 to 750 C. for a time sufiicient to dehydrogenate said compound.

9. Process as claimed in claim 8, wherein said compound is at least one selected from the group consisting of ethyl benzene, isopropylbenzene, Z-ethylpyridine, 2- ethylthiophene and diethyl benzene.

10. Process as claimed in claim 8 wherein M is tungstem.

11. Process as claimed in claim 8 wherein M is chromi- 12. Process as claimed in claim 8 wherein A is potasslum.

13. Process as claimed in claim 8 wherein said catalyst is 1.0WO3'0.6Nb2O5.

14. Process as claimed in claim 8 wherein said catalyst is 1.0Cr O -5Nb 0 15. Process as claimed is 1.0Cr O -3Nb O 16. Process as claimed in claim 8, carried out in the presence of sufiicient oxygen to maintain a 20 to 180 per cent heat balance.

17. Process as claimed in claim 8 carried out at a space velocity of about 0.1 to 10 v./hr./v.

18. Process as claimed in claim 8 wherein said catalyst is coated on a substrate.

19. Process as claimed in claim 18 wherein said support is at least one selected from the group consisting of silicon carbide, alumina, silica gel and fused alumina.

20. Process of oxidatively dehydrogenating at least one compound selected from the group consisting of ethane, propane, propene, n-butane, butene, isobutane, n-pentane, l-pentene, 2-pentene, isopentane, 3-methyl-2-butene,, nhexane, hexene, n-heptane, monomethylhexane, monomethylhexene, n-octane, n-octene, monomethylheptane, dimethylhexane, n-decane, S-methylnonane, 2,2,3-trimethylpentane, 2,4,4-trimethylpentene, cyclopentane, cyclopentene, methylcyclopentane, cyclohexane, methylcyclohexane, ethylcyclohexane, 1,3-dimethylcyclohexane, 1,4- dimethylcyclohexane, n-propylbenzene, which comprises contacting such compound with oxygen in the presence of a catalyst as claimed in claim 1 at an elevated temperature for a time suflicient to increase the ethylenic unsaturation of said compound.

in claim 8 wherein said catalyst References Cited UNITED STATES PATENTS 3/1967 Bajars 260669 X 3/1967 Bajars 260-669 X UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No 3 ,371 ,125 February 27 1968 Joseph Francis McMahon It is certified that err gr appears in the above identified patent. and that said Letters Patent are hereby corrected as shown below: p,

,,Column 4 line 32 "atoms" should read atom line 65 "oxfgent" should read oxygen Column 5, line 23, "imputs shou'lgaread inputs line 38 "Be Mg and Ra" should read H, Fr, Be Mg and Ra line 64 "chormates" should read chromates Column 6 line 60 "V/Nb" should read W/Nb Column 10, line 4, "dihydrogenated" should read dehydrogenated Signed and sealed this 2nd day of December 1969.

(SEAL) Eduri rd M. Fletcher, Jr. WILLIAM E. SCHUYLER, JR.

Attesting Officer Commissioner of Patents 

